Gas turbine engine with fan variable area nozzle for low fan pressure ratio

ABSTRACT

A gas turbine engine includes a fan section with twenty (20) or less fan blades and a fan pressure ratio less than about 1.45.

CROSS REFERENCE TO RELATED APPLICATIONS

The present disclosure is a continuation in part of U.S. patentapplication No. 13/314365, filed Dec. 8, 2011.

BACKGROUND

The present invention relates to a gas turbine engine, and moreparticularly to a turbofan engine having a fan variable area nozzle(VAFN) which moves axially to change a bypass flow path area thereof.

Conventional gas turbine engines generally include a fan section and acore engine with the fan section having a larger diameter than that ofthe core engine. The fan section and the core engine are disposed abouta longitudinal axis and are enclosed within an engine nacelle assembly.

Combustion gases are discharged from the core engine through a coreexhaust nozzle while an annular fan flow, disposed radially outward ofthe primary airflow path, is discharged through an annular fan exhaustnozzle defined between a fan nacelle and a core nacelle. A majority ofthrust is produced by the pressurized fan air discharged through the fanexhaust nozzle, the remaining thrust being provided from the combustiongases discharged through the core exhaust nozzle.

The fan nozzles of conventional gas turbine engines have a fixedgeometry. The fixed geometry fan nozzles are a compromise suitable fortake-off and landing conditions as well as for cruise conditions. Somegas turbine engines have implemented fan variable area nozzles. The fanvariable area nozzle provide a smaller fan exit nozzle diameter duringcruise conditions and a larger fan exit nozzle diameter during take-offand landing conditions. Existing fan variable area nozzles typicallyutilize relatively complex mechanisms that increase overall engineweight to the extent that the increased fuel efficiency therefrom may benegated.

SUMMARY

A gas turbine engine according to an exemplary aspect of the presentdisclosure includes a core nacelle defined about an engine centerlineaxis, a fan section with twenty (20) or less fan blades, a fan nacellemounted at least partially around the fan section and the core nacelleto define a fan bypass flow path for a fan bypass airflow, the fanbypass airflow having a fan pressure ratio of the fan bypass airflowduring engine operation, the fan pressure ratio less than about 1.45.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a fan variable areanozzle movable relative to the fan nacelle to vary a fan nozzle exitarea.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a controlleroperable to reduce the fan nozzle exit area at a cruise flightcondition. Additionally or alternatively, the controller may be operableto control the fan nozzle exit area to reduce a fan instability.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the fan variable area nozzle defines a trailing edgeof the fan nacelle.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the fan variable area nozzle may be axially movablerelative to the fan nacelle.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a gear system drivenby a core engine within the core nacelle to drive the fan section.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the fan section may define a corrected fan tip speedless than about 1150 ft/second.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the core engine may include a low pressure turbinewhich defines a pressure ratio that is greater than about five (5).Additionally or alternatively, the core engine may include a lowpressure turbine which defines a pressure ratio that is greater thanfive (5).

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a gear system drivenby a core engine within the core nacelle to drive the fan section withinthe fan nacelle, the gear system defines a gear reduction ratio ofgreater than or equal to about 2.3.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a gear system drivenby a core engine within the core nacelle to drive the fan within the fannacelle, the gear system defines a gear reduction ratio of greater thanor equal to about 2.5.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the engine may further comprise a gear system drivenby a core engine within the core nacelle to drive the fan within saidfan nacelle, the gear system defines a gear reduction ration of greaterthan or equal to 2.5.

In a further non-limiting embodiment of any of the foregoing gas turbineengine embodiments, the fan bypass airflow may define a bypass ratiogreater than about six (6). Additionally or alternatively, the fanbypass airflow may define a bypass ratio greater than about ten (10).Additionally or alternatively, the bypass flow may define a bypass ratiogreater than ten (10).

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will becomeapparent to those skilled in the art from the following detaileddescription of the currently preferred embodiment. The drawings thataccompany the detailed description can be briefly described as follows:

FIG. 1A is a general schematic partial fragmentary view of an exemplarygas turbine engine embodiment for use with the present invention;

FIG. 1B is a rear view of the engine;

FIG. 1C is a side view of the engine integrated with a pylon;

FIG. 1D is a perspective view of the engine integrated with a pylon;

FIG. 2A is a sectional side view of the VAFN in a closed position;

FIG. 2B is a sectional side view of the VAFN in an open position; and

FIG. 3 is a graph of a bypass duct normalized cross-sectional areadistribution.

FIG. 4 is a graph of a Effective Area Increase vs. Nozzle Translation;

FIG. 5 is a graph of a duct area distribution;

FIG. 6A is schematic geometric view of the auxiliary port location;

FIG. 6B is schematic geometric view of the auxiliary port entranceangle; and

FIG. 6C is schematic geometric view of a VAFN outer surface curvature.

DETAILED DESCRIPTION

FIG. 1A illustrates a general partial fragmentary schematic view of agas turbofan engine 10 suspended from an engine pylon P within an enginenacelle assembly N as is typical of an aircraft designed for subsonicoperation.

The turbofan engine 10 includes a core engine within a core nacelle 12that houses a low spool 14 and high spool 24. The low spool 14 includesa low pressure compressor 16 and low pressure turbine 18. The low spool14 drives a fan section 20 through a gear train 22. The high spool 24includes a high pressure compressor 26 and high pressure turbine 28. Acombustor 30 is arranged between the high pressure compressor 26 andhigh pressure turbine 28. The low and high spools 14, 24 rotate about anengine axis of rotation A.

The engine 10 is preferably a high-bypass geared aircraft engine. In onedisclosed, non-limiting embodiment, the engine 10 bypass ratio isgreater than about six (6), with an example embodiment being greaterthan about ten (10), the gear train 22 is an epicyclic gear train suchas a planetary gear system or other gear system with a gear reductionratio of greater than about 2.3 and the low pressure turbine 18 has apressure ratio that is greater than about 5. In one disclosedembodiment, the engine 10 bypass ratio is greater than about ten (10:1),the turbofan diameter is significantly larger than that of the lowpressure compressor 16, and the low pressure turbine 18 has a pressureratio that is greater than about 5:1. Low pressure turbine 18 pressureratio is pressure measured prior to inlet of low pressure turbine 18 asrelated to the pressure at the outlet of the low pressure turbine 18prior to exhaust nozzle. The gear train 22 may be an epicycle gear trainsuch as a planetary gear system or other gear system with a gearreduction ratio of greater than about 2.5:1. It should be understood,however, that the above parameters are only exemplary of one embodimentof a geared architecture engine and that the present invention isapplicable to other gas turbine engines including direct driveturbofans.

Airflow enters a fan nacelle 34, which at least partially surrounds thecore nacelle 12. The fan section 20 communicates airflow into the corenacelle 12 to power the low pressure compressor 16 and the high pressurecompressor 26. Core airflow compressed by the low pressure compressor 16and the high pressure compressor 26 is mixed with the fuel in thecombustor 30 and expanded over the high pressure turbine 28 and lowpressure turbine 18. The turbines 28, 18 are coupled for rotation with,respective, spools 24, 14 to rotationally drive the compressors 26, 16and through the gear train 22, the fan section 20 in response to theexpansion. A core engine exhaust E exits the core nacelle 12 through acore nozzle 43 defined between the core nacelle 12 and a tail cone 32.

The core nacelle 12 is supported within the fan nacelle 34 by structure36 often generically referred to as Fan Exit Guide Vanes (FEGVs). Abypass flow path 40 is defined between the core nacelle 12 and the fannacelle 34. The engine 10 generates a high bypass flow arrangement witha bypass ratio in which approximately 80 percent of the airflow enteringthe fan nacelle 34 becomes bypass flow B. The bypass flow B communicatesthrough the generally annular fan bypass flow path 40 and is dischargedfrom the engine 10 through a fan variable area nozzle (VAFN) 42 whichdefines a fan nozzle exit area 44 between the fan nacelle 34 and thecore nacelle 12 at a fan nacelle end segment 34S of the fan nacelle 34downstream of the fan section 20.

Thrust is a function of density, velocity, and area. One or more ofthese parameters can be manipulated to vary the amount and direction ofthrust provided by the bypass flow B. The Variable Area Fan Nozzle(“VAFN”) 42 operates to effectively vary the area of the fan nozzle exitarea 44 to selectively adjust the pressure ratio of the bypass flow B inresponse to a controller C. Low pressure ratio turbofans are desirablefor their high propulsive efficiency. However, low pressure ratio fansmay be inherently susceptible to fan stability/flutter problems at lowpower and low flight speeds. The VAFN 42 allows the engine to change toa more favorable fan operating line at low power, avoiding theinstability region, and still provide the relatively smaller nozzle areanecessary to obtain a high-efficiency fan operating line at cruise.

A significant amount of thrust is provided by the bypass flow B due tothe high bypass ratio. The fan section 20 of the engine 10 may includetwenty (20) or less fan blades 20B which is designed for a particularflight condition—typically cruise at about 0.8 Mach and about 35,000feet. The flight condition of 0.8 Mach and 35,000 ft, with the engine atits best fuel consumption—also known as “bucket cruise Thrust SpecificFuel Consumption (‘TSFC’)”—is the industry standard parameter of lbm offuel being burned divided by lbf of thrust the engine produces at thatminimum point. “Low fan pressure ratio” is the pressure ratio across thefan blade alone, without the Fan Exit Guide Vane (“FEGV”) system 36. Thelow fan pressure ratio as disclosed herein according to one non-limitingembodiment is less than about 1.45. “Low corrected fan tip speed” is theactual fan tip speed in ft/sec divided by an industry standardtemperature correction of [(Tambient deg R)/518.7)̂0.5]. The “Lowcorrected fan tip speed” as disclosed herein according to onenon-limiting embodiment is less than about 1150 ft/second.

As the fan blades 20B within the fan section 20 are efficiently designedat a particular fixed stagger angle for an efficient cruise condition,the VAFN 42 is operated to effectively vary the fan nozzle exit area 44to adjust fan bypass air flow such that the angle of attack or incidenceon the fan blades is maintained close to the design incidence forefficient engine operation at other flight conditions, such as landingand takeoff to thus provide optimized engine operation over a range offlight conditions with respect to performance and other operationalparameters such as noise levels.

The VAFN 42 is separated into at least two sectors 42A-42B (FIG. 1B)defined between the pylon P and a lower Bi-Fi splitter L which typicallyinterconnects a larger diameter fan duct reverser cowl and a smallerdiameter core cowl (FIGS. 1C and 1D). Each of the at least two sectors42A-42B are independently adjustable to asymmetrically vary the fannozzle exit area 44 to generate vectored thrust. It should be understoodthat although two segments are illustrated, any number of segments mayalternatively or additionally be provided.

In operation, the VAFN 42 communicates with a controller C or the liketo adjust the fan nozzle exit area 44 in a symmetrical and asymmetricalmanner. Other control systems including an engine controller or aircraftflight control system may also be usable with the present invention. Byadjusting the entire periphery of the VAFN 42 symmetrically in which allsectors are moved uniformly, thrust efficiency and fuel economy aremaximized during each flight condition. By separately adjusting thecircumferential sectors 42A-42B of the VAFN 42 to provide anasymmetrical fan nozzle exit area 44, engine bypass flow is selectivelyvectored to provide, for example only, trim balance or thrust controlledmaneuvering enhanced ground operations or short field performance.

The VAFN 42 generally includes an auxiliary port assembly 50 having afirst fan nacelle section 52 and a second fan nacelle section 54 movablymounted relative the first fan nacelle section 52. The second fannacelle section 54 axially slides along the engine axis A relative thefixed first fan nacelle section 52 to change the effective area of thefan nozzle exit area 44. The second fan nacelle section 54 slidesaftward upon a track fairing 56A, 56B (illustrated schematically inFIGS. 1C and 1D) in response to an actuator 58 (illustratedschematically). The track fairing 56A, 56B extend from the first fannacelle section 52 adjacent the respective pylon P and the lower Bi-Fisplitter L (FIG. 1D).

The VAFN 42 changes the physical area and geometry of the bypass flowpath 40 during particular flight conditions. The bypass flow B iseffectively altered by sliding of the second fan nacelle section 54relative the first fan nacelle section 52 between a closed position(FIGS. 2A) and an open position (FIG. 2B). The auxiliary port assembly50 is closed by positioning the second fan nacelle section 54 in-linewith the first fan nacelle section 52 to define the fan nozzle exit area44 as exit area F0 (FIG. 2A).

The VAFN 42 is opened by moving the second fan nacelle section 54aftward along the track fairing 56A, 56B away from the first fan nacellesection 52 to open an auxiliary port 60 which extends between the opensecond fan nacelle section 54 relative the first fan nacelle section 52to essentially provide an increased fan nozzle exit area 44 exit areaF1. That is, the exit area Fl with the port 60 is greater than exit areaFO (FIG. 2B).

In one disclosed embodiment, the auxiliary port 60 is incorporated intothe exhaust system of a high bypass ratio commercial turbofan enginewithin the bypass duct aft of the Fan Exit Guide Vanes (FEGVs; FIGS. 2A,2B). The auxiliary port 60 is located in the aft section of the bypassduct outer wall.

Referring to FIG. 3, the bypass duct area distribution, the effectivearea increase vs. translation (FIG. 4), area distribution (FIG. 5), andauxiliary port 60 location (FIG. 6A) and wall curvatures (FIG. 6B-6C)are tailored to provide a proper flow-field that allows the auxiliaryport 60 to obtain the required additional effective exit area. Theauxiliary port 60 will essentially double the effective area gain due totranslation. The auxiliary port 60 provides a relatively low weightmethod of providing increased exit area to control the fan operatingline without causing high system losses or unacceptable aircraftinstallation issues. By tailoring the bypass duct area distribution andouter wall curvature, the desired maximum effective area increase isachieved before the stroke of the auxiliary port 60 reaches itseffective area increase limit.

The auxiliary port exit plane 44B (defined as the plane between thestationary section's trailing edge and the moving sections leading edge)initially has an opening in which the exit plane normal vector isnear-axial, but as the stroke increases, the normal vector becomes moreinclined and approaches a near-radial vector. Once the exit plane normalhas become near-radial, the maximum auxiliary port effectiveness hasbeen reached. Once this point is reached, the rate of the effective areavs. translation changes from steep slope of the “well designed port” theshallow rate of the “main nozzle only”, since additional area will beprovided through the main nozzle 44A due to the inward slope of the corenacelle 12. A well designed auxiliary port nozzle will achieveapproximately +25% effective area before the port effectiveness limit isreached. That is, there is a limited range of stroke in which theauxiliary port doubles the rate of additional effectiveness. Outside ofthis range, the rate of additional effectiveness may be equivalent to atranslating nozzle that has no auxiliary port. Or put another way, theauxiliary port reduces the stroke necessary for a pure translatingnozzle to achieve a desired effective area.

Referring to FIG. 5, the cross-sectional area at the auxiliary port 60is greater than the maximum required effective area of the VAFN 42 andthe bypass duct area distribution is tailored to ensure the ductcross-sectional area forward of the auxiliary port 60 is greater thanthe port opening cross-sectional area. This avoids a situation where anupstream internal cross-section becomes the controlling flow area (i.e.is smaller than the exit area), which can lead to operational limits andstructural issues.

Referring to FIG. 6A, the auxiliary port 60 in the disclosed embodiment,is located no more forward than 0.1 DEL_X/L_DUCT defined from a point Dat the largest radius Rmax of the annular fan bypass flow path 40defined by the second fan nacelle section 54. Rmax is defined throughpoint D and perpendicular to the engine axis A. Point D in the disclosednon limiting embodiment is located on an inner wall surface 541 of thesecond fan nacelle section 54 when the second fan nacelle section 54 isin a closed position. DEL_X is the axial distance to the forward mostpoint of the auxiliary port 60 from Rmax. L_DUCT is the overall axiallength of the annular fan bypass flow path 40. The angle between themean port line and the fan duct outer wall is relatively low to providewell-behaved, low loss exit flow. In the disclosed embodiment, theauxiliary port 60 entrance angle (Theta_in) relative to the fan bypassduct OD wall, is less than 20 degrees (FIG. 6B) while the outer VAFNsurface has an R_ARC/CHORD >0.7 where R_ARC is a radial distance fromthe engine axis A to a radial outer wall surface 54O of the second fannacelle section 54 and CHORD is the chord length of the second fannacelle section 54. (FIG. 6C). The curvature of the outer wall surface54O near the auxiliary port 60 promotes flow through the auxiliary port60. In one disclosed embodiment, the stroke of the second fan nacellesection 54 necessary to obtain an additional 20% effective exit area isapproximately 8.4 inches.

In operation, the VAFN 42 communicates with the controller C to move thesecond fan nacelle section 54 relative the first fan nacelle section 52of the auxiliary port assembly 50 to effectively vary the area definedby the fan nozzle exit area 44. Various control systems including anengine controller or an aircraft flight control system may also beusable with the present invention. By adjusting the axial position ofthe entire periphery of the second fan nacelle section 54 in which allsectors are moved simultaneously, engine thrust and fuel economy aremaximized during each flight regime by varying the fan nozzle exit area.By separately adjusting the sectors of the second fan nacelle section 54to provide an asymmetrical fan nozzle exit area 44, engine bypass flowis selectively vectored to provide, for example only, trim balance,thrust controlled maneuvering, enhanced ground operations and shortfield performance.

The foregoing description is exemplary rather than defined by thelimitations within. Many modifications and variations of the presentinvention are possible in light of the above teachings. The preferredembodiments of this invention have been disclosed, however, one ofordinary skill in the art would recognize that certain modificationswould come within the scope of this invention. It is, therefore, to beunderstood that within the scope of the appended claims, the inventionmay be practiced otherwise than as specifically described. For thatreason the following claims should be studied to determine the truescope and content of this invention.

1. A gas turbine engine comprising: a core nacelle defined about anengine centerline axis; a core engine at least partially disposed withinthe core nacelle; a fan section with twenty (20) or less fan blades; agear system driven by the core engine to drive said fan section; a fannacelle mounted at least partially around said fan section and said corenacelle to define a fan bypass flow path for a fan bypass airflow, saidfan bypass airflow having a fan pressure ratio of the fan bypass airflowduring engine operation, said fan pressure ratio less than about 1.45; avariable fan nozzle axially movable relative to the fan nacelle, thevariable fan nozzle including at least two sectors; and a controller forindependently adjusting each of the at least two sectors.
 2. (canceled)3. The engine as recited in claim 1, wherein the controller is operableto reduce said fan nozzle exit area at a cruise flight condition.
 4. Theengine as recited in claim 1, wherein said controller is operable tocontrol said fan nozzle exit area to reduce a fan instability.
 5. Theengine as recited in claim 1, wherein said fan variable area nozzledefines a trailing edge of said fan nacelle.
 6. The engine as recited inclaim 1, wherein said fan variable area nozzle is axially movablerelative to said fan nacelle.
 7. (canceled)
 8. The engine as recited inclaim 1, wherein said fan section defines a corrected fan tip speed lessthan about 1150 ft/second.
 9. The engine as recited in claim 1, whereinsaid core engine includes a low pressure turbine which defines a lowpressure turbine pressure ratio that is greater than about five (5). 10.The engine as recited in claim 7, wherein said core engine includes alow pressure turbine which defines a low pressure turbine pressure ratiothat is greater than five (5).
 11. The engine as recited in claim 1,further comprising a gear system driven by a core engine within the corenacelle to drive said fan section within the fan nacelle, said gearsystem defines a gear reduction ratio of greater than or equal to about2.3.
 12. The engine as recited in claim 1, further comprising a gearsystem driven by a core engine within said core nacelle to drive saidfan within said fan nacelle, said gear system defines a gear reductionratio of greater than or equal to about 2.5.
 13. The engine as recitedin claim 1, further comprising a gear system driven by a core enginewithin said core nacelle to drive said fan within said fan nacelle, saidgear system defines a gear reduction ratio of greater than or equal to2.5.
 14. The engine as recited in claim 1, wherein said fan bypassairflow defines a bypass ratio greater than about six (6).
 15. Theengine as recited in claim 1, wherein said fan bypass airflow defines abypass ratio greater than about ten (10).
 16. The engine as recited inclaim 1, wherein said fan bypass airflow defines a bypass ratio greaterthan ten (10).
 17. The engine as recited in claim 1, wherein the atleast two segments includes a first segment defined between the pylonand the lower Bi-Fi and a second segment defined between the pylon andthe lower Bi-Fi on a side opposite the engine centerline axis from thefirst segment.
 18. The engine as recited in claim 1, including anauxiliary port defining an semi-annular opening between the at least twosectors and the fan nacelle.
 19. The engine as recited in claim 18,wherein the variable fan nozzle defines a first bypass flow area and theauxiliary port defines a second bypass flow area for increasing bypassflow at a desired opening position of the at least two sectors.
 20. Theengine as recited in claim 18, wherein a cross-sectional area of theauxiliary port is greater than a maximum area of the bypass flowpathforward of the auxiliary flow path.
 21. The engine as recited in claim1, wherein the at least two sectors are independently adjustable to varya fan exit nozzle asymmetrically to generate a vectored thrust.